Apparatus for distilling oil shale and the like



June 5,1945. E. H. RECORDS ETAL APPARATUS FOR DISTILLING OIL SHALE AND THE LIKE Filed March 17, 1942 INVENTOR ELM/52 H. EEcoQ/J n/ 1 5 E.LOUTTIT /gmfi Q M ATTORNEY Patented June 5, 1945 'zsmsis APPARATUS,

FOR DISTILLING OIL AND THE LIKE SEHALE Elmer H. Recordsand JamesE. Louttit,

Tacoma, Wash Application March 17, 1942, Serial No. 435,002

3 Claims.

This invention deals with the art of recovering hydrocarbon oils and other valuable byproducts from oil shale, bituminous sands and like raw materials, and it has reference more particularly to apparatus utilizing superheated steam solely as the heating medium and wherein vital chemical reactions are brought about by the addition to the shale, sands or other material under dis tillation, of certain solid,,liquid or gaseous materials that are high in hydrocarbons of a desired nature, whereby to increase the yield ofhydrocarbon oils andlow boiling oils of value; it being the principal object of this invention to provide an improved apparatus for carrying on a process which leads to the recovery of a greater quantity and a superior quality of products and .by-products than heretofore has been possible.

Explanatory to the present invention, it will here be stated that the organic matterthat makes up the hydrocarbon oils in oil shale are classified as pyrobitumens, and these, upon destructive distillation, yield oils of various character which have been termed Kerogen orgreen 011.? Kerogen, as such, has a large and complex molecule, which, of itself, has little practical value. The present process, or treatment, utilizing comparatively low'pressuresand moderate heat, has for an object and provides for the recovery of these oils in a cured or refined condition. At the same time, the reaction'is sup-- plied with vital and necessary compounds so that reformation in a. single operation increases the yield of valuable hydrocarbon oils and the pro-.

duction of the same with a large volume of low boiling oil of'extreme value as motor. fuel. 7

This reaction is a simultaneous decomposition of the complex Kerogen molecule and a polymerization of products of such decomposition to reform as a large volume of saturated naphtha and paraffin molecules of both closed and open chain types. This is made possible by the use of coal, lignite or similar volatile carbonaceoussubstances so placed in the reaction chamber that the evolving volatiles contact the destructively distilled oil shale simultaneously; coal, lignite and such hydrocarbons being, used because they supply a continuous flow of such evolving vapors and require approximately the same length oi time for destructive distillation as is required by 'the oil shale.

The destructive distillation of the coal or lig- V nite. in the base of the retort results in a con- (Cl- 20F121) decomposed Kerogen, results in a high degree of saturation of the resulting compounds. In accordance with the process practised by the present apparatus, superheated steam at temperatu'res ranging from 700 F.- to 1800" F. and-at pressures from atmospheric to fifty pounds is used. Under the conditions of this process. the superheated steam as the sole heating medium is desirable because of its high'speciflc heat and aclo. tive hydrogen and oxygen content with the absence of inertgases, and another advantage in its/use-is that heat carried into the mass by the superheated steam is uniformly distributed, and although the temperatures are controlled so that decomposition ,of the shale takes place, there are no hot walls or zones of sufllcient temperature to allow cracking of the -final vaporous products formed in the final reaction. This has resulted in amaterial decreasein the length of time of treatment encountered in other methods or proc- I esses. Furthermore, it has been found that the increased yield of hydrocarbon oil is due,to the enrichening effect of the reactions of the process and that such oils are much easier refined and a decrease in refinery losses result'therefrom.

The present application is a continuation in part of ourapplication filed on October 18, 1937,

under Serial No. 169,594, and which has been given Patent No. 2,276,342. In accomplishing the objects of the present invention, we have provided the improved details of construction, the preferred forms of which are illustrated in the accompanying drawing, where- Fig. 1 is a vertical sectional view of apparatus for carrying out the present process.

Fig. 2 is a sectional detail of an-alternative form of construction. 7

' Referring more in detail to the drawing:

I designates, in its entirety, the reaction retort; 2, a condenser; 3, a decanter; and 4, a steam superheater. The reactlon'retort l comprises a cylindrical vessel preferably built of steel boiler 'plateand comprising an outer shell I0 and an inner shell. of lesser diameter. These are coaxially disposed, to provide an intermediate, annular space or expansion chamber l8, and at their lower ends are welded together as at 5 to form a gas-tight joint and are drawn inwardly to form a throat leading to an outlet or opening I! of restricted diameter. on the inside face of the inner shell H at the beginning of the throat or restricted portion, vertically spaced baflie rings l3 and H are welded within the shell. The lower to edges of these-baffles are spaced from the walls designated at 18.

ofthe shell for the purpose of deflecting the discharging residue toward the axial center, and

also to serve as protective guards overlying a plu-' rality of ports l which open through the shell II from the intermediate space l6, or expansion;

chamber. into the reaction chamber.

At'its'upperend, the edge or the shell i0 is turned inwardly and is welded to the inner shell to form a steam and gas-tight connection therewith, and there are one or more pipes ll'leading from-the vsuperheater 4 into the upper end of the expansion chamber l6, and the flow or steam through each pipe is controlled'by a valve as Fitted over the upper end of the shell H, which extends somewhat above the shell l0 and expansion chamberjli, is a closure or lid is which is seated in a gas-tight joint, and is normally held clamped in place' by a cross" clamp bar 20 and a jack screw 2| mounted on the bar to en ga e the lid.

Upon removal of thelid, the reaction chamber is opened for charging, and this may be done by means of 'a bucket as designated'at 23. A pipeend with a T-fitting 24, having the cross head portion disposedin a'vertical plane. The upper end of the cross head is closed by means of a. plug 25 while the lower end is open. A pressure tank 28 is arranged somewhat above the reaction chamber'to contain a supply or oil which may be conducted through a pipe 2'! into the reaction chamber to the fitting 24, and'is then conducted downward through a pipe 28 to cause the oil to,

spray into the mass being treated slightly above .the coal or lignite zone. Suitable supports 01" brackets 20 may be utilized to brace, and support the lower end of the pipe 28.

that isinthe moving steam to heat quickly, are overcome.

Assuming the reaction structed, and the ports-arranged as illustrated, the method or operation,-briefly described, is asrollows: T I

First, the charging lid I! is removed and the reaction chamber is first charged with spent orbroken raw shalein'an amount suflicientjto cover the baiiles It, thus filling the lower end zone which is designated within the bracket C. Over this zone V, the required amount or coal or lignite is charged a to flll the zone designated within'the bracket B. Then broken ofl shale is charged into the main part of the reaction chamber to near the upper end. thus filling the zone designated within the bracket A. The charging thus being completed,

the lid u is clamped in place and tightened with I the bar and jack screw provided;

In'the' meantime, superheated steam has-been V provided in superheater l at the temperatures and pressures required. Valve II is then opened, alt

Y lowing the superheated steam to-pass into the expansion chamber l6 and through the apertures l5 into the bottom of the reaction chamber and 1 into thecharge that is to be treated. Upon pass-.

ing upward through the charge, the superheated steam starts decomposition to coal and shale, 1osing a considerable portion or its specific heat inthe .process. As the volatiles contaiiied in the coal rise through the shale mass, they, in combination with other released from the 'steamand shale,- reform into hydrocarbon molecules or gaseous and liquid nature. These are thoroughly mixed by turbulence in the upper portion of the reaction chamber, and pass out through the T- fltting 24, pipe- 22 and valve 81, which has been opened, and enter the condenser 2 which may be of an air cooled or water cooled type. r The condensed hydrocarbons and steam then pass through a seal pipe 39 leading 1mm the'lower chamber to be so conend of the condenser into the decanting vessel 3."

The hydrocarbon oils of this process, being lighten than water, break away from the water or con It is preferred that'the entire reaction chamber f be covered with a suitable insulation 30 of the spun slag type. I'he reaction chamber proper will be supported by the columns II and the brick work 32, and material discharged from the reaction chamber, through the opening H! at the lower end thereof falls into a .quenlchchamber D. The opening i2 is provided with. a gas-tight discharge door which may be manually or mechanically moved, in guideways in a horizontal frame 34 into and from closed'position. In the -:ers through a pipe 38.

'present instance, the door is shown as bein conveyor may be made to serve one or more reaction chambers placed in a row i! occasion arises.

- In Fig. 2 is illustrated an alternative construc-' tion, which is designed to maintain a hotzone at the base or discharge end of the retort.y--To ac: complish this, a pipe II is lead ofl from steam pipe ",andiorms a steam coil llin the rather elongated and somewhat tapered base portion '2 of the retort. The lower end of thecoil is-turned upwardly and opens into the shale bed.-

' By use or this cofl, there will always be a zoneoi? high temperature at "the base of the retort,

which is desirable, and the undesirable results, due

densed steam in the decanter and rise to the tol of the vessel, as indicated, there to be drawn of! through-a pipe 40 and conducted therebyto prop er storage tanks. A pipe 4i leading from the-decanter at a lower level than the pipe ll is used 'to maintain a desired water level. The noncon densible gases formed are of high B. t. 11. content and pass from the condenser into proper gas hold- At proper intervals, oily hydrocarbons stored in Y the pressure tank 28 may, upon opening a valve 1 21' on pipe 2'l, be injected under pressure'into the distillingmass through pipes 21 and 28. ,Thls

' period of treatment varies with the type or'oil shale .used, but it has been round that this process will take considerably less time of reaction than that required by pro cesses that resort to external 1 heating methods. Upon completion or the proper V treatment, then the valve or valves II. are closed,

as is also the valve 31. 1he'discharge trap is then openedrand the shale in the bottom 0! the retort, in zone c, the-carbonized coal in nine B;

together with the spent shale in zone A. then fall by gravity into the chamber D and intorthe conveyor 38 and may be carried thereby to waste.

In drawing the charge, it is desirable, however,-

to leave enough 01' the spent shale of zone A in the reaction chamber to form a base/or zone C.

for the next charge which is cycled in a manner Similartothatdescribed above.

- In the use of a super-heated steam italics been certain types of oil shales, it may be desirable to use pressures somewhat higher. Temperatures of the incoming steam for general operation will be approximately 1200 F., but is has been found that in order to take advantage of the exothermic and endothermic cycles of thereacting mass,

temperatures from 700 to 1800 F. may be necessary. In no case should the temperature be so great that secondary reactions predominate.

It has been found by the present method of processing that a much larger proportion of parafiln hydro-carbons are formed having the general formula C2H2n+2; such parafllns being of the open chain or saturated type. It has also been found that there is a higher proportion of saturated monocyclic or naphthene series of compounds of the general formula cum; .these being of ring or closed chain type.

These types of saturated compounds are very desirable as they are quite easily converted into motor fuel of high anti-knock rating as well as .ance with the claims appended hereto, and in construing these claims, it is desired that the word '"coal" shall apply equally to coal, lignite or other carbonaceous materials capable of the same results, while oil-shale shall be understood to be any of the various oil-shales, bituminous sands and like raw materials capable of the upper end and to discharge at its lower end, a steam jacket enclosing the reaction chamber, and having inlet ports'opening therefrom into the lower end of the chamber, means for supplying superheated steam in controlled amount to the jacket for admittance to thechamber, deflector plates secured to the chamber walls to overlie the said steam inlet ports-without interference with incoming steam, means for eiiecting the deliveryof an oil into the chamber within the lower end area. a condenser and means for conducting the products of distillation from the upper end of the chamber to the condenser.

2. An apparatus for the recovery of hydrocar in controlled amount to the jacket for admittance to the chamber, deflector plates secured to the chamber walls to overlie the said steam inlet ports without interference with incoming steam, means for effecting the delivery of an oil intothe chain.-

ber within the lower'end area. a condenser and means for conducting the products of distillation from the upper end of the chamber to the condenser, and. a decanter arranged to receive liquid from the condenser.

uses herein explained in connection with this I Having thus described our invention, what we 3. An apparatus for the recovery of hydrocarbon oils from oilshale and the like comprising a reaction chamber adapted to be charged at its upper end and to discharge at the lower end thereof, a steam. jacket enclosing the reaction chamber and having ports opening therefrom into the reaction chamber near its lower end, means for supplying superheated steam in controlled amounts to the jacket for admittance to the chamber through, the por s. a condenser, an outletfrom the upper end or the reaction cham-' her to the condenser, and a heating coil located in the lower end portion of the reaction chamber betweenthe discharge opening and the steam I inlet ports for maintaining a zone of high heat.

, ELMER H. RECORDS.

JAMES E. LOU'I'I'IT. 

